Trend towards the democratization of simulation tools

The computer-aided engineering (CAE) industry seeing a trend towards the democratization of the simulation tools.
The aim is to bring the power of prediction computer model simulation experts as a way to guide the early cycle product design.

Traditionally, it is an assessment of the manufacturing process complicated casted product. simulation experts generally need to assess the two-step problems computational fluid dynamic (CFD).

Altair is its democratizing software simulations Click2Cast CAE solutions. This product is part of Altair solidThinking portfolio, which seeks to CAE tools into the hands of non-experts on the use of advanced simulation early in the development cycle. These tools offer intuitive user interfaces (UI), aiming to have both novices and experts trained in CAE matter of hours.

“The traditional approach to training days and one targeting experts place more than the software on the problem at hand,” said Ravi Kunju, solidThinking Vice President of Altair. “Click2Cast brings the right experience to the design and manufacturing engineers with simplicity so that anyone can run a simulation in the organization.”

Click2Cast focusing specifically on those who design and manufacture the product casted. It will give engineers and colleagues the ability to determine how it will be possible to manufacture their designs early in the development cycle.

“Manufacturing is disconnected with the product design cycle,” said Kunju. “There will be many designers to develop something without assessing if makeable or not. We want to tools for early design phase to the designers so they can see if the product is castable or stampable . this is when Click2Cast fits in. “

Kunju explained that there can be a significant risk to the design concept did not assess manufacturing feasibility. In this case, you know what defects show up (as porosity, air entrapments, cold shots or blow holes) when the product hits production facility for metal casting. But Click2Cast, designers, engineers and manufacturers can:

-Assess The conceptual design can be manufactured

-Compare concept designs to others for manufacturing

-Reduce manufacturing tryouts create design guidelines

-Assess placement of gates, vents, risers and runners

-The detailed Validate near the end of the development cycle


Global metal casting Market 2016 Industry Trends, Sales, Supply, Demand, Analysis and Forecast to 2021

The World metal casting Industry report comprehensive account of the Metal Casting global market. Details such as the size, key, segmentation, SWOT analysis, most influential trends, market and business environment mentioned in this report. In addition, this report features tables and figures leaves a clear view of the market Metal Casting. Features of the updated data report details key companies’ product, revenue figures, and sales. Furthermore, these data along with the World Metal solutions market revenue and forecasts. The business model strategies of key market businesses also include Metal Casting. key strengths, weaknesses, and threats shaping the leading players in the market are also included in the research report.

The report provides a detailed overview of the key market segments. The market segments fastest and slowest growth covered in this report. The main opportunities are emerging on the World Metal Casting fastest growing market segments are also covered in this report. All segments and sub-segments of the market size, share, and forecast provided in this report. In addition, the region-wise segmentation and trends driving the leading geographical region and the region has been emerging in this report.

The study of the global market Metal Casting also features a history of the tactical action mergers, acquisitions, cooperation, and partnerships in the market. Senior analysts valuable suggestions about investing strategically in research and development or help new entrants based players penetrate emerging sectors in the Metal Casting market. Investors will get a clear view of the main players in this industry and their future forecasts. In addition, readers will get a clear view of the high demand and the unmet needs of consumers will improve the market growth.


Late 20th Century of Metal Casting

1970 is the Semi-Solid metal worker process (SSM) conceived at Massachusetts Institute of Technology. It combines elements of aspects of forging solutions.

1971 Japanese to develop V-Process molding. This method uses unbonded sand and vacuum. Rheocasting 1971 is being developed by Massachusetts Institute of Technology.

1971 passes US Congress Clean Air Act and OSHA, the Occupational Health and Safety Act.

The first production in 1972 is Austempered ductile iron (ADI) components produced by Wagner Castings Company.

1974 Fiat introduces the in-mold process for ductile iron treatment.

1976 is compacted graphite iron (CGI), iron with graphite particles elongated with rounded edges and roughened surfaces, developed in the UK has characteristics of both gray and ductile iron.

1982 The Hot Box into binder system.

1993 occurs first foundry applications of plasma ladle refiner (melting and refining in one vessel) at Maynard steel casting Company in Milwaukee, WI. Babcock and Wilcox
1995, Barberton, OH, patent lost foam vacuum casting process to produce stainless steel castings with low carbon content.

1996 cast metal matrix composites which was first used in automobile production model in brake rotors for the Lotus Elise.

1997 Electromagnetic casting process developed by Argonne and Inland Steel Corporation. Electromagnetic edge containment significantly reduces energy expenditure and costs in steel production.


Early 20th Century of Metal Casting

1906 is the first electric arc furnace used in the United States Holcomb Steel Co. in Syracuse, NY.

1913 The first stainless steel true molten Harry Brearley in Sheffield, England.

1913 Crucible steel casting Co.’s Lansdown, PA plant installs the first low-frequency electric furnace for melting special.

1923 Formation of the International Committee of Foundry Technical Association in Zurich, Switzerland.

1924 Dr. WH Hatfield invents 18/8 stainless steel (18% chromium, 8% nickel). University of Michigan professors 1930s pioneer Spectrography for metal analysis.

1930 is the first high-frequency electric coreless induction furnace in the United States installed in Lebanon steel foundry in Lebanon, PA.

1940 is wood flour into practice as an additive foundry sand.

A 1947 Shell Process, invented by J. Croning Germany during WWII, discovered by US officials and made public.

1948 Development of ductile iron, cast iron with graphite structure completely spheriodal.

US patent granted in 1949 to KD Millis, AP Gagnebin and NB Pilling International Nickel Company to develop ductile iron.

System 1953 is to make the hot box and apply only cores developing curing, eliminating the need for dielectric drying oven.

HF 1958 Shroyer granted a patent for the full mold process, the predecessor of the expendable pattern (lost foam) casting process.

Compactibility 1960s and methylene blue clay testing development on green sand control. Also developed at this time is high-pressure molding processes and fast-set no bake binders for sand.

1964 is the first molding machine Disamatic into.

A Scanning Electron Microscope 1965 invented the Engineering Department at Cambridge University in England.

1965 cast metal matrix composites are initially poured by International Nickel Company in Sterling Forest, NY, by Pradeep Rohatgi.

Process 1968 is The Box Cold introduced Toriello L. and J. Robins your heart to produce high.marking.


Metal casting and separation

Molten metal is poured into molds using different types of ladles, or in the production of high volume, automated pouring furnaces. Metal is poured into the “runners” (channel into the mold cavity) until the bush is complete runner. Provides the “riser” additional reservoir of metal feed to counteract the shrinkage that occurs as the casting begins to cool. When the metal has cooled enough to hold its shape solutions, it is separated from the mold by mechanical means or manual. If using sand molds, the process is often referred to as shakeout or knockout, and large amounts of dust generated.

A range of finishing processes are usually performed. These include:

♦ cleaning to remove residual sand, oxides and surface scale, often at or tumble shot blasting;

♦ heat treatment, including annealing, tempering, normalizing and quenching (in water or oil) to improve the mechanical properties;

♦ metal removing surface blemishes or over, (eg, flash lead to incomplete closure mold or burrs left from riser detached), grinding, sawing or arc air (oxy-propane cutting);

♦ correction of defects by welding;

♦ machining;

♦ non destructive testing to check for defects;

♦ priming, painting or application of a rust preventive coating.

Recycling industry is a large amount of mold and core sand internally for reuse. The processing involves removing tramp metal and the sand returns to a condition that allows it to use again for mold or core production.


The 19th Century of Metal Casting

-1809 Has developed a centrifugal casting AG Eckhardt of Soho, England.

-1815 The cupola was introduced in the US in Baltimore, MD.

-1818 First cast steel produced by the crucible process in the United States at the Valley Forge Foundry. Aluminum

-1825, the most common metal in the earth’s crust, is isolated.

-1826 Seth Boyden of Newark, NJ, is the first to develop processes and produce “blackheart” malleable iron.

-1831 In Cincinnati, OH, William Garrard establishes the first commercial steel crucible operation in the US is the first molding machine

-1837 dependable on the market and used by the S. Jarvis Adams Company in Pittsburg. -1845 The open hearth furnace to develop.

-1851 Sir Henry Bessemer and both William Kelly compose simple converter that uses blasts of air to burn off impurities, silicon, manganese and excess carbon in pig iron. While Kelly is the first to use converter, Bessemer receives US patents. Kelly creates patent priority in 1857.

-1863 Metallography, the etching, polishing, metal surfaces and microscopic evaluation, developed by Henry C. Sarby Sheffield, England. The first process is to physically examine the projection surface for analysis quality.

-1867 James Nasmythe develops foundry ladle appliances-tilted, worker safety and increasing operational economy. Sandblasting

-1870 first used to clean large castings by RE Tilghman of Philadelphia.

-1880-1887 The Sly tumbling mill development. The first cleaning machine for small castings. This mill greatly reduce the time required for manual cleaning operations and produced a finer finished product.

-1896 American Foundrymen’s Association (renamed American Foundrymen Society in 1948 and is now called the American Foundry Society) made.

-1897 Investment solutions are arrived at BF Philbrook of Iowa. It uses wear dental inlays.


Pattern Materia used in metal casting

Patterns may be built from different materials. Each material has its own advantages, limitations, and scope. Some materials used for making patterns: wood, metals and alloys, plastic, plaster of Paris, plastic and rubber, wax and resins. To be suitable for use, should the material pattern to be:

1. easily worked, molded and joined

2. Light weight

3. Strong, durable

4. hard and resistant to wear and abrasion

5. Resistant to corrosion, and chemical reactions

6. dimensionally stable and unaffected by changes in temperature and humidity

7. Available at low cost

gating and risering system

- are the usual pattern materials wood, metal, and plastic. The pattern material most commonly used wood, since it is readily available and low weight. Also, it can be shaped easily and is relatively cheap.

- The main disadvantage of wood to absorb the moisture, which can cause distortion and dimensional changes.

- Araldite is a new material for making pattern, which is a reference to a range of engineering and structural epoxy, acrylic, and polyurethane adhesives.


Middle Ages to 1800 of Metal Casting

Castle Dillenburg in Germany in 1455 is the first use of cast iron pipe carrying water.

1480 Birth Vannoccio Biringuccio (1480-1539), the “father of the foundry industry,” in Italy. He is the first man to document the foundry process in writing.

Saugus Iron Works in 1642, the first iron foundry America (and the second industrial plant), based near Lynn, Massachusetts. The first American iron casting, the Saugus pot, then poured.

Englishman Abraham Darby in 1709 creates the first foundry flask true for molding sand and loam.

1720 Rene Antoine de Reaumur develops first malleable iron, known today as “European Whiteheart.”

1730 Abraham Darby is the first to use coke as a fuel melting furnace in Coalbrookdale, England.

1750 Benjamin Huntsman reinvents the process cast steel crucible in England. This process is the first, in which the steel is melted completely, producing a uniform composition within the melt. Since the metal is melted completely, it also allows for the production of alloy steel, as can the additional elements in the alloy to the crucible during melting. It was completed in advance steel production through a combination of creating and tempering, and never reached the state of molten metal.
Foundrymen 1776 Charles Carroll, James Smith, George Taylor, James Wilson, George Ross, Philip Livingston and Stephen Hopkins signed the American Declaration of Independence.

1794 The first use of the Cupola in founding iron. Invented by John Wilkinson of England, was the original metal-cladding and used steam engines to the air blast provide.


Metal melting of metal casting

Molten metal is prepared in a variety of furnaces, the choice is determined by the quality, quantity and throughput required.

♦ electric induction furnaces are the most common type used for batch melting ferrous, copper and super alloys. In this method involves the use of an electric current surrounding crucible that holds the metal charge. Furnace sizes range from <100 kg up to 15 tons. For the production of super alloys and titanium, may melt in a vacuum chamber to prevent oxidation.

♦ cupola used solely by iron foundries for continuous production of molten iron. Cupola consists of a bed shaft coking established. Metal, coke and limestone are charged alternately into the furnace from the top. Trickles through the bed of molten metal picking up carbon coke required, although impurities reacts with the limestone to form slag waste. Both metal and slag tapped continuously out at the bottom. Metal throughput of 1 to 45 tonnes per hour to reach the UK.

♦ electric arc furnaces are still used by some UK ferrous foundries, mainly producing steel castings, although most have been replaced by induction furnaces. Furnaces are 3-100 tons of capacity in use in the UK. Involves the design used in a bath holding electrodes are inserted. The heat generated causes a charge between the electrodes creating the metal to melt.

♦ Rotary furnaces are relatively rare in the UK but is used in some iron foundries. The furnace consists of a horizontal cylindrical steel shell mounted on rollers and lined with refractory material. The furnace is fired using gas or oil from one head and the body is rotated slowly furnace during melting.

♦ shaft and resistance Gas-fired furnaces used for melting aluminum. A shaft furnaces provide a continuous melting and cracking ability, useful at high production facilities. Resistance furnaces employed to melt the small batches.

♦ Gas and oil-fired crucible furnaces used for melting small batch of copper and aluminum alloys, although oil-fired units as popular now and tend to be limited to smaller foundries. Unlike the main furnace containing molten metal tapped into a ladle for solutions, the crucible is lifted out (or pops out) the heating chamber and the molten metal can be poured directly into the mold.


Origins of Metal Casting

Metal Technologies has compiled a brief timeline of metal solutions to give you an overview of the long history and proud of our industry. Since the discovery, metal casting has played a crucial role in the development and promotion of human culture and civilization. After 5000 years of technological advances, plays metal solutions to most in our lives everyday and it is more necessary than ever.

3200 BC A frog is copper, the oldest known solutions exist, cast in Mesopotamia. 2000 BC Iron out.

800-700 BC First demonstration of China iron.

645 BC The earliest known molding sand (Chinese).

233 BC iron plowshares which poured in China.

500 AD Cast crucible steel was first produced in India, but the process is lost until 1750 when he reinvents Benjamin Huntsman in England.